Buckling resistant current collector

ABSTRACT

A wire mesh including a warp which includes a first nickel alloy wire having a first peak tensile strength; and a weft which includes a wire including nickel having a second peak tensile strength, wherein the first peak tensile strength is greater than or equal to the second peak tensile strength, is provided. A current collector and a zinc-air battery that includes the wire mesh are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/518,830, filed on Apr. 13, 2017, which is a U.S. National PhaseApplication under 35 U.S.C. § 371 of International Application No.PCT/US2015/055609, filed on Oct. 14, 2015, which claims the benefit ofU.S. Provisional Application No. 62/064,551, filed Oct. 16, 2014, theentire contents of which are hereby incorporated by reference in theirentirety.

FIELD

The present technology is generally related to batteries. In particular,the present technology is related to current collectors that resistbuckling upon insertion into a battery can.

SUMMARY

In one aspect, a wire mesh is provided including a warp which includes afirst nickel alloy wire having a first peak tensile strength; and a weftwhich includes a wire including nickel having a second peak tensilestrength, wherein the first peak tensile strength is greater than orequal to the second peak tensile strength.

In another aspect, an expanded metal mesh is provided including a nickelmetal alloy which includes at least 90 wt % nickel and less than 10 wt %aluminum.

In yet another aspect, a zinc-air battery is provided, including a wiremesh current collector which includes a warp including a first nickelalloy wire having a first peak tensile strength and a weft including awire which includes nickel and having a second peak tensile strength,wherein the first peak tensile strength is greater than or equal to thesecond peak tensile strength.

In one aspect, a zinc-air battery is provided, which includes a wiremesh current collector comprising a wire warp and a wire weft, whereinthe current collector exhibits at least one or more of the followingproperties: (a) a metal of the wire mesh is substantially insoluble inan aqueous caustic electrolyte; (b) a wire of the warp or weft prior toincorporation in the mesh exhibits a hardness of from about 130 to about375 Brinell; (c) a wire of the warp or weft prior to incorporation inthe mesh exhibits a resistivity of from about 2×10⁻⁷ Ωm to about 5×10⁻⁷Ωm at 20° C.; (d) a wire of the warp or weft prior to incorporation inthe mesh exhibits a peak tensile strength of greater than 140 ksi; and(e) a wire of the warp or weft prior to incorporation in the meshexhibits a Young's Modulus of from about 180 GPa to about 240 GPa.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional, schematic view depicting an exemplary wiremesh of an embodiment of the present disclosure.

FIG. 2 is a cross-sectional, schematic view depicting an exemplaryelectrochemical cell of an embodiment of the present disclosure.

FIG. 3 is a graph of the percentage of batteries having an impedancemeasurement above a given threshold versus the crimp height for thenickel alloy current collector batteries and nickel wire controlbatteries.

DETAILED DESCRIPTION

Various embodiments are described hereinafter. It should be noted thatthe specific embodiments are not intended as an exhaustive descriptionor as a limitation to the broader aspects discussed herein. One aspectdescribed in conjunction with a particular embodiment is not necessarilylimited to that embodiment and may be practiced with any otherembodiment(s).

As used herein, “about” will be understood by persons of ordinary skillin the art and will vary to some extent depending upon the context inwhich it is used. If there are uses of the term which are not clear topersons of ordinary skill in the art, given the context in which it isused, “about” will mean up to plus or minus 10% of the particular term.

The use of the terms “a,” “an,” and “the” and similar referents in thecontext of describing the elements (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Recitation of ranges of values herein are merely intended toserve as a shorthand method of referring individually to each separatevalue falling within the range, unless otherwise indicated herein, andeach separate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein may beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the embodiments and does not pose alimitation on the scope of the claims unless otherwise stated. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential.

Ratios, concentrations, amounts, and other numerical data may bepresented herein in a range format. It is to be understood that suchrange format is used merely for convenience and brevity and should beinterpreted flexibly to include not only the numerical values explicitlyrecited as the limits of the range, but also to include all theindividual numerical values or sub-ranges encompassed within that rangeas if each numerical value and sub-range is explicitly recited. Forexample, 5 to 40 mole % should be interpreted to include not only theexplicitly recited limits of 5 to 40 mole %, but also to includesub-ranges, such as 10 mole % to 30 mole %, 7 mole % to 25 mole %, andso forth, as well as individual amounts, including fractional amounts,within the specified ranges, such as 15.5 mole %, 29.1 mole %, and 12.9mole %, for example.

As used herein, the terms “warp” and “weft” refer to the orthogonal runsof the mesh, i.e. the lengthwise runs and the orthogonal runs whereinthe weft runs are inserted over-and-under the warp runs. However, theterms are not used in a manner entirely consistent with cloth weaving,because the mesh described herein is open on each direction afterbonding of the orthogonal runs of wire. That is, the warp and the weftare interchangeable once the mesh is released from the loom duringproduction. Accordingly, as defined herein, the warp and weft areinterchangeable with regard to the types of materials forming each; theterms only signify the orthogonal runs of materials.

The term “tensile strength,” as used herein, is defined in accordancewith the pertinent art and relates to the maximum stress that a materialmay withstand while being stretched or pulled. Tensile strength isdefined as a stress, which is measured as force per unit area. Thetensile strength is generally expressed in terms of psi (pounds persquare inch) or ksi (kips per square inch; 1 kip=1000 psi). Tensilestrength as referred to herein is the tensile strength as measuredaccording to ASTM C1557—Standard Test Method for Tensile Strength andYoung's Modulus of Fibers.

The term “mesh density,” as used herein, is defined as the weight ratioof wire mesh to solid metal, where the wire mesh and the solid have thesame or similar thickness and surface area.

The term “aperture size” of the wire refers to the distance between twoneighboring warp or weft wires, measured in the center of the aperture.

The term “mesh count” of the wire refers to the number of apertures perEnglish inch (25.4 mm).

The term “wire diameter” refers to the diameter of the wire measuredbefore weaving.

The term “pitch” of the wire refers to distance between the middle pointof two adjacent wires or the sum of the aperture width and the one wirediameter.

The term “mesh thickness” refers to the average thickness of the meshand is based on the wire diameter, weaving process and weaving pattern.

As used herein, the phrase “substantially insoluble” refers to anyamount of a wire mesh not dissolved in the electrolyte.

It has now been found that a wire material, which is stiffer whencompared to conventional materials, may be used as a cathode currentcollector in air batteries. The stiffer wire increases battery productyields during manufacture by lowering the incidence of batteries havingpoor contact between the current collector and side walls of the batterycan, as indicated by impedance measurements above a given threshold. Thestiffer provides for a greater number of cells having sufficiently low,initial impedance measurements and a lower number of battery rejections.Without being bound by theory, it is believed that the increased tensilestrength and buckling resistance of this wire, when woven into a mesh,provides minimal deformation of the current collector leading toenhanced contact to the sidewall of the battery can, thereby reducingthe proportion of high impedance cells. Such batteries also tend toexhibit better performance characteristics than control batteries (i.e.control batteries—those without the stiffer wire material).

In one aspect, a wire mesh is provided, which includes warp wires andweft wires, wherein the warp wires include a first nickel alloy wirehaving a first peak tensile strength, and the weft wires include nickelhaving second peak tensile strength, and wherein the first peak tensilestrength is greater than or equal to the second peak tensile strength.In some embodiments, the first peak tensile strength is greater than thesecond peak tensile strength. In other embodiments, the first peaktensile strength is equal to the second peak tensile strength. In someembodiments, the weft wires and the warp wires are interchangeable.

Referring particularly to FIG. 1, an enlarged cross-section of oneembodiment of the wire mesh is shown. The wire mesh 100 consists of warpwires 110, which are composed of a first nickel alloy wire having afirst peak first tensile strength, and weft wires 120, composed ofnickel having second peak having a second tensile strength. The warpwires are described in terms of wire diameter d¹, pitch p¹ and aperturesize w¹. The weft wires are described in terms of wire diameter d²,pitch p² and aperture size w². The mesh is open on each direction afterbonding of the orthogonal runs of wire thereby rendering the warp andthe weft interchangeable. The wire mesh may be used in the constructionof batteries, e.g., metal-air batteries. The wire mesh may form eitherelectrode or current collector for either electrode in a battery. Whenused as a cathode or cathode current collector, the wire mesh isintroduced to a battery can such that distal ends of the mesh eachcontact interior walls of the battery can. When materials having a lowtensile strength are used, the mesh buckles at an unacceptably high rateleading to high impedance and cell failure. The wire mesh describedherein has high tensile strength. The use of the wire mesh describedherein therefore results in reduced buckling incidence, resulting inimpedance values remaining below specified limits, and a lower failurerate.

The wires of the mesh are composed of suitable conductive materialscapable of interfacing, as an electrode or a current collector for anelectrode, e.g., with the cathode assembly of an electrochemical cell.For example, the wire mesh may include wires made of nickel-basedmaterials.

In addition to nickel, the wires of the mesh may contain othercomponents, such as for example, other metals. In some embodiments, thewires may be in the form of an alloy. For example, the weft wireincluding the first nickel alloy wire may include nickel and aluminum.In some embodiments, the first nickel alloy wire may include at leastabout 85 wt % nickel. This includes at least about 90 wt %, at leastabout 91 wt %, at least about 92 wt %, at least about 93 wt %, at leastabout 94 wt %, or at least about 95 wt % nickel. In some embodiments,the first nickel alloy wire may include less than about 15 wt %aluminum. This includes less than about 12 wt %, less than about 10 wt%, less than about 9 wt %, less than about 8 wt %, less than about 7 wt%, less than about 6 wt %, less than about 5 wt %, less than about 4 wt%, or less than about 3 wt % aluminum. In some embodiments, the firstnickel alloy includes at least 85 wt % nickel and less than 15 wt %aluminum. This includes at least about 85 wt % nickel and less thanabout 15 wt % aluminum, at least about 88 wt % nickel and less thanabout 12 wt % aluminum, at least about 90 wt % nickel and less thanabout 10 wt % aluminum, at least about 95 wt % nickel and less thanabout 5 wt % aluminum, or at least about 96 wt % nickel and less thanabout 4 wt % aluminum. In other embodiments, the first nickel alloy wireincludes from about 90 wt % to about 99 wt % nickel and from about 1 wt% to about 10 wt % aluminum. This includes from about 91 wt % to about98 wt % nickel and from about 2 wt % to about 9 wt % aluminum, fromabout 93 wt % to about 97 wt % nickel and from about 3 wt % to about 7wt % aluminum, from about 95 wt % to about 96 wt % nickel and from about4 wt % to about 5 wt % aluminum, and ranges between any two of thesevalues or less than any one of these values. In some embodiments, thefirst nickel alloy wire includes at least 90 wt % nickel and less than10 wt % aluminum. In other embodiments, the first nickel alloy wirecomprises from about 93 wt % to about 97 wt % nickel and from about 3 wt% to about 7 wt % aluminum.

In addition to nickel and aluminum, the first nickel alloy wire mayinclude other suitable components. For example, the first nickel alloymay include at least one of copper, iron, manganese, carbon, silicon,sulfur, and titanium. The other suitable components, if present, may beincluded in a total amount from about 0 wt % to about 2 wt %. Thisincludes from about 0.00001 wt % to about 1 wt %, from about 0.0001 wt %to about 0.5 wt %, from about 0.001 wt % to about 0.1 wt %, or fromabout 0.01 wt % to about 0.08 wt %, and ranges between any two of thesevalues or less than any one of these values.

In some embodiments, the first nickel alloy wire is a fully annealedwire. In other embodiments, the first nickel alloy wire is a half-hardannealed wire. In some embodiments, the first nickel alloy wire is adrawn out wire. In some embodiments, the first nickel alloy wire is anextruded wire. In some embodiments, the first nickel alloy wire is acold-formed or a hot-formed wire. The first nickel alloy wire may beannealed at a temperature of from about 400° C. to about 1400° C. forfrom 0 minutes to 10 hours, depending on the thickness and presence ofalloys. In some embodiments, the first nickel alloy wire is annealed ata temperature of from about 500° C. to about 1200° C., from about 550°C. to about 1100° C., from about 600° C. to about 1000° C., from about700° C. to about 900° C., or from about 750° C. to about 850° C., andranges between any two of these values or less than any one of thesevalues. In some embodiments, the annealing temperature for the firstnickel alloy wire is from about 500° C. to about 600° C. In otherembodiments, the annealing temperature for the first nickel alloy wireis from about 600° to 800° C. In some embodiments, the first nickelalloy wire is annealed for a time of greater than about 5 minutes,greater than about 30 minutes, greater than about 45 minutes, greaterthan about 1 hour, greater than about 5 hour, or greater than about 10hour, and ranges between any two of these values or less than any one ofthese values. In some embodiments, the annealing time is from about 1hour to about 8 hour. In some embodiments, the first nickel alloy wireis an annealed wire. In some embodiments, the first nickel alloy wire isa half-hard wire.

In some embodiments, the wire mesh includes warp wires which includewires made of nickel and may have greater than 80% nickel. This includesgreater than about 80%, greater than about 85%, greater than about 90%,greater than about 91%, greater than about 92%, greater than about 93%,greater than about 94%, greater than about 95%, greater than about 96%,greater than about 97%, greater than about 98%, or greater than about99% nickel. In one embodiment, the wire which includes nickel hasgreater than 99% nickel. In some embodiments, wire which includes nickelhas greater than 99.5% nickel. In one embodiment, the weft wire includesnickel and has greater than 99% nickel. In some embodiments, the weftwire includes nickel and has greater than 99.5% nickel.

In some embodiments, the wire which includes nickel is a second nickelalloy wire. In some embodiments, the wire which includes nickel mayfurther include other components. For example, the wire which includesnickel may be a second nickel alloy wire which includes at least one ofcopper, iron, manganese, carbon, silicon, sulfur, titanium, magnesium,molybdenum, arsenic, or vanadium. In some embodiments, the first and thesecond nickel alloy wires have the same composition. In someembodiments, the first and the second nickel alloy wires have differentcomposition. In some embodiments, the first nickel alloy wire, thesecond nickel alloy wire, or both, are coated with a coating of same orother conductive material.

In addition to nickel or nickel containing alloys described herein, thewire mesh may include wires made of other materials such asnickel-plated stainless steel; nickel-clad stainless steel; cold-rolledsteel plated with nickel; INCONEL® (a non-magnetic alloy of nickel);pure nickel with minor alloying elements (e.g. Nickel 200 and relatedfamily of Nickel 200 alloys such as Nickel 201, etc.), all availablefrom Huntington Alloys, and DURANICKEL® 301, available from SpecialMetals. In one embodiment, some noble metals may also find use asplating, cladding, or other coating for can metals, including coveringthe wires, the wires plated with nickel, and wires before or afterfabricating the can.

The wire mesh described herein has low electrical resistivity whichreadily allows the movement of electric charge. The electricalresistivity, in general, quantifies how strongly a given materialopposes the flow of electric current. In some embodiments, the firstnickel alloy wire has a resistivity, when measured at 20° C. of fromabout 5×10⁻⁸ Ωm to about 1×10⁻⁶ Ωm. This includes a resistivity of fromabout 1×10⁻⁸ Ωm to about 9×10⁻⁷ Ωm, from about 2×10⁻⁷ Ωm to about 5×10⁻⁷Ωm, from about 3×10⁻⁷ Ωm to about 4×10⁻⁷ Ωm, and ranges between any twoof these values or less than any one of these values. In someembodiments, the first nickel alloy wire has a resistivity of from about2×10⁻⁷ Ωm to about 5×10⁻⁷ Ωm at 20° C.

The individual wires or the wire mesh may be subjected to additionalconditioning or treatment methods to improve their properties. Forexample, the wires described herein may be subjected to annealing priorto, or after, formation of the mesh. The term annealing generally refersto a heat treating process which may modify the crystal structure and/orharden or soften the material for improved fabricating. The temperatureand duration of the heat will vary according to the composition andthickness of the wire. Thus in one embodiment, the wire including nickelmay be an annealed wire.

In some embodiments, the wire including nickel is a fully annealed wire.In other embodiments, the wire including nickel is a half-hard annealedwire. In some embodiments, the wire including nickel is a drawn outwire. In some embodiments, the wire including nickel is an extrudedwire. The wire including nickel may be annealed at a temperature of fromabout 400° C. to about 1400° C. for from 0 minutes to 10 hours,depending on the thickness and presence of alloys. In some embodiments,the wire including nickel is annealed at a temperature of from about500° C. to about 1200° C., from about 550° C. to about 1100° C., fromabout 600° C. to about 1000° C., from about 700° C. to about 900° C., orfrom about 750° C. to about 850° C., and ranges between any two of thesevalues or less than any one of these values. In some embodiments, theannealing temperature for the wire including nickel is from about 500°C. to about 600° C. In other embodiments, the annealing temperature forthe wire including nickel is from about 700° to 950° C. In someembodiments, the wire including nickel is annealed for a time of greaterthan about 5 minutes, greater than about 30 minutes, greater than about45 minutes, greater than about 1 hour, greater than about 5 hours, orgreater than about 10 hours, and ranges between any two of these valuesor less than any one of these values. In some embodiments, the annealingtime is from about 30 minutes to about 4 hours. In some embodiments, thewire including nickel is an annealed wire. In some embodiments, the wireincluding nickel is a half-hard wire.

The technology provides wire mesh having a first nickel alloy wirehaving a high tensile strength (prior to incorporation in the mesh) ofgreater than about 120 ksi. This includes embodiments in which the firstnickel alloy wire has a peak tensile strength of greater than 130 ksi,greater than 140 ksi, greater than 150 ksi, greater than 160 ksi,greater than 170 ksi, greater than 180 ksi, greater than 190 ksi,greater than 200 ksi, greater than 210 ksi, greater than 220 ksi, orgreater than 230 ksi. In some embodiments, the first nickel alloy wirehas a peak tensile strength of less than 400 ksi, less than 350 ksi,less than 300 ksi, less than 250 ksi, less than 240 ksi, less than 230ksi, less than 220 ksi or less than 210 ksi. In some embodiments, thefirst nickel alloy wire has a peak tensile strength of from about 120ksi to about 350 ksi, from about 130 ksi to about 300 ksi, from about140 ksi to about 250 ksi, from about 150 ksi to about 240 ksi, fromabout 175 ksi to about 230 ksi, from about 200 ksi to about 225 ksi,from about 210 ksi to about 220 ksi, and ranges between any two of thesevalues or less than any one of these values. In some embodiments, thefirst nickel alloy wire has a peak tensile strength of greater than 140ksi. In other embodiments, the first nickel alloy wire has a peaktensile strength of greater than 180 ksi. In some embodiments, the firstnickel alloy wire has a peak tensile strength of greater than 200 ksi.In some embodiments, the first nickel alloy wire has a peak tensilestrength of greater than 210 ksi. In some embodiments, the first nickelalloy wire has a peak tensile strength of less than 350 ksi. In otherembodiments, the first nickel alloy wire has a peak tensile strength ofless than 300 ksi. In some embodiments, the first nickel alloy wire hasa peak tensile strength of less than 230 ksi. In some embodiments, thefirst nickel alloy wire has a peak tensile strength of from about 140ksi to about 250 ksi. In some embodiments, the first nickel alloy wirehas a peak tensile strength of from about 200 ksi to about 225 ksi.

The technology provides wire mesh with a second nickel alloy wire havinga tensile strength of greater than about 60 ksi. This includesembodiments in which the second nickel alloy wire has a peak tensilestrength of greater than 70 ksi, greater than 80 ksi, greater than 90ksi, greater than 100 ksi, greater than 110 ksi, greater than 120 ksi,greater than 130 ksi, greater than 150 ksi, greater than 180 ksi,greater than 130 ksi, or greater than 200 ksi. In some embodiments, thesecond nickel alloy wire has a peak tensile strength of from about 50ksi to about 240 ksi, from about 60 ksi to about 220 ksi, from about 70ksi to about 200 ksi, from about 80 ksi to about 150 ksi, from about 100ksi to about 145 ksi, from about 110 ksi to about 140 ksi, or from about120 ksi to about 130 ksi, and ranges between any two of these values orless than any one of these values. In some embodiments, the secondnickel alloy wire has a peak tensile strength of greater than 60 ksi. Insome embodiments, the second nickel alloy wire has a peak tensilestrength of greater than 80 ksi. In some embodiments, the second nickelalloy wire has a peak tensile strength of greater than 100 ksi. In someembodiments, wherein the second nickel alloy wire has a peak tensilestrength of greater than 120 ksi. In some embodiments, the second nickelalloy wire has a peak tensile strength of greater than 200 ksi. In someembodiments, the second nickel alloy wire has a peak tensile strength ofgreater than 150 ksi. In some embodiments, the second nickel alloy wirehas a peak tensile strength of from about 80 ksi to about 150 ksi. Insome embodiments, the second nickel alloy wire has a peak tensilestrength of from about 110 ksi to about 140 ksi.

The hardness of the wire mesh will vary depending on the bond strength,the method of testing and the plane of recordation. In some embodiments,a wire of the warp or weft prior to incorporation in the mesh exhibits amicrohardness of about 120 kgf/mm² to about 450 kgf/mm². This includes amicrohardness of from about 130 kgf/mm² to about 395 kgf/mm², about 160kgf/mm² to about 350 kgf/mm², about 170 kgf/mm² to about 300 kgf/mm²,about 180 kgf/mm² to about 270 kgf/mm², about 190 kgf/mm² to about 260kgf/mm², about 200 kgf/mm² to about 250 kgf/mm², about 220 kgf/mm² toabout 240 kgf/mm², and ranges between any two of these values. Themicrohardness may be tested using Vickers hardness test (orinterconverted to other hardnesses such as measured by the Knoophardness test) using standard guidelines, e.g. the ASTM E384 guidelines.In some embodiments, in order to obtain the desired properties, thewires or the mesh may be further subjected to age hardening. In someembodiments, a wire of the warp or weft prior to incorporation in themesh exhibits a hardness of from about 100 to about 450 Brinell. Thisincludes from about 120 to about 400 Brinell, about 130 to about 375Brinell, about 150 to about 350 Brinell, about 200 to about 300 Brinell,or about 230 to about 270 Brinell, and ranges between any two of thesevalues.

In some embodiments, the warp wire which is the first nickel alloy has amicrohardness from about 160 kgf/mm² to about 350 kgf/mm², while theweft which is the wire comprising nickel, or the second nickel alloy hasa microhardness from about about 90 kgf/mm² to about 150 kgf/mm². Thisincludes the first nickel alloy having a microhardness from about 170kgf/mm² to about 300 kgf/mm², about 180 kgf/mm² to about 270 kgf/mm²,about 190 kgf/mm² to about 260 kgf/mm², about 200 kgf/mm² to about 250kgf/mm², about 220 kgf/mm² to about 240 kgf/mm², and ranges between anytwo of these values. This also includes the second nickel alloy having amicrohardness from about 95 kgf/mm² to about 150 kgf/mm², about 95kgf/mm² to about 120 kgf/mm², about 95 kgf/mm² to about 110 kgf/mm², andranges between any two of these values. For example, the warp may have amicrohardness of about 200 kgf/mm², while the weft may have amicrohardness of about 100 kgf/mm².

The technology provides wire mesh with a first nickel alloy wire havingyield strength of greater than about 20 ksi with an offset of 0.2%. Thisincludes yield strength of greater than about 40 ksi, greater than about60 ksi, greater than about 80 ksi, greater than about 100 ksi, greaterthan about 120 ksi, greater than about 140 ksi, greater than about 180ksi, greater than about 200 ksi or greater than about 220 ksi. In someembodiments, the technology provides a wire mesh with a first nickelalloy having a yield strength of from about 20 ksi to about 300 ksi.This includes a yield strength of from about 40 ksi to about 250 ksi,from about 60 ksi to about 220 ksi, from about 80 ksi to about 200 ksi,of about 100 ksi to about 180 ksi, of about 120 ksi to about 140 ksi,and ranges between any two of these values or less than any one of thesevalues.

Depending on the diameter of the wire, the mesh count of the wire meshmay range from about 10×10 wires per inch to about 100×100 wires perinch. This includes a mesh count of about 12×12 wires per inch to about80×80 wires per inch, about 16×16 wires per inch to about 60×60 wiresper inch, about 20×20 wires per inch to about 50×50 wires per inch, fromabout 30×30 wires per inch to about 40×40 wires per inch, about 12×100wires per inch to about 100×12 wires per inch, about 15×40 wires perinch to about 40×15 wires per inch, about 16×60 wires per inch to about60×16 wires per inch, or from about 20×40 wires per inch to about 40×20wires per inch, and ranges between any two of these values or less thanany one of these values. In some embodiments, the mesh count of the wiremesh is from about 16×16 wires per inch to about 60×60 wires per inch.In other embodiments, the mesh count of the wire mesh is from about30×30 wires per inch to about 40×40 wires per inch. In some embodiments,the mesh count of the wire mesh is from about 16×60 wires per inch toabout 60×16 wires per inch.

The wires of the mesh may be configured to have the similar or differentdiameters. For example, the warp wires may have similar diameter orlarger or smaller diameter than the diameter of the weft wires. In someembodiments, the wire including nickel has a cross-section diameter (d²)greater than the diameter (d¹) of the first nickel alloy wire. Forexample, the cross-section diameters of the wire including nickel andthe first nickel alloy wire may have a ratio of about 1:9 to about 9:1.This includes a ratio between about 1:4 and about 4:1, more suitablybetween about 1:3 and about 3:1, and even more suitably between about1:2 and about 2:1. In some embodiments, the cross-section diameters ofthe wire which includes nickel and the first nickel alloy wire have aratio of about 1:1 to about 2:1, about 1.5:1 to about 1:1, or about1.25:1 to about 1:1. In some embodiments, the cross-section diameters ofthe wire including nickel and the first nickel alloy wire are equal orabout equal.

In order to improve the conductivity of the mesh, it is designed toprovide a high amount of conductive material per unit of surface area ofa conductive region or electrode. This property may be expressed interms of the mesh density of the wire mesh which is a measure of apercentage of area with fill or conductive lines relative to the totalsurface area of a conductive region. As an example and not by way oflimitation, the wire mesh may have a mesh density from about 0.001% toabout 20% of the total surface area of the conductive region. Thisincludes a mesh density of from about 0.05% to about 10%, from about0.01% to about 1%, from about 0.1% to about 0.5%, from about 0.2% toabout 0.4% or from about 0.25% to about 0.35% of the total surface areaof the conductive region, and ranges between any two of these values orless than any one of these values.

Various methods may be used to prepare the mesh. For example, the warpand the weft wires may be left unwoven or may be woven in a desiredpattern. Standard weaving techniques known in the art may be used toweave the warp and weft wires. Generally, the wires are positioned to beequidistant from each other so as to form a uniform weaving pattern, butneed not necessarily be so. Suitable weaving patterns include, but arenot limited to, a plain weave, a basket weave, a twill weave, a satinweave, a herringbone weave, a leno weave, a rep weave, a rib weave, awarp rib weave, a Dutch weave, and velour weave as known to one skilledin the art, or a combination of any two or more thereof. In someembodiments, the wire mesh is a woven mesh having a plain square weave,a twill square weave, plain Dutch weave, or a twill Dutch weave, orcombinations thereof. In some embodiments, the mesh may include anycombination of two or more weave patterns. The weave pattern may be asparse weave or a dense weave. The sparse weave pattern will result inlarger openings in the wire mesh which is desirable for certainapplications. The dense weave will result in smaller openings in thewire mesh which may be required for certain other applications.

The woven or unwoven network of wires may be subjected to additionalprocessing such as thermal bonding, chemical bonding or mechanicalbonding to form the mesh. For example, the mesh may be formed by coldcalendaring of the warp and the weft. Calendering refers to the passingof the wire between rollers under pressure and optionally at hightemperatures. Calendering helps flatten the high points at theintersection of the wires, reduce the thickness of the wire cloth andgive the material a smooth surface. In some embodiments, the mesh isformed by crimping the wires at the intersection such that corrugationsare formed in the wires so as to lock the wires in place.

In some embodiments, the mesh is formed by the thermal bonding of thewarp and the weft. Thermal bonding refers to a process wherein theintersections of the weft and warp wires are heated to high temperaturesor soldered together. The heating may be done without the application ofpressure. The temperature of the thermal bonding will vary depending onthe composition of the wire and/or the melting point of the wirematerials. In some embodiments, the intersections of the warp and weftwires may be soldered using suitable soldering materials. In someembodiments, the mesh wires are subjected to welding. In otherembodiments, the mesh wires may be subjected to brazing.

In some embodiments, the mesh is formed by coating of the mesh with asuitable coating of electrical conductive materials such as othermetals. Thus, in some embodiments, the woven or unwoven network or warpand weft wires may be coated with another metal. Examples of metalssuitable for coating the mesh include silver, gold, copper, aluminum,nickel, tungsten, zinc, iron, platinum, tin, steel and other electricconductive metals or alloys thereof or combinations thereof. In oneembodiment, the mesh is coated with nickel. The coating is applied in away so as to keep the wires in position.

The thickness of the wire mesh may be measured in terms of the thicknessof the individual wires or the combined thickness of the warp and weftwires. In some embodiments, the wire mesh may have a thickness fromabout 0.01 μM to about 200 μM. This includes a thickness from about 0.05μM to about 150 μM, about 0.1 μM to about 100 μM, about 1 μM to about 70μM, about 2 μM to about 50 μM, about 5 μM to about 20 μM, about 10 μM toabout 18 μM, about 14 μM to about 17 μM, or about 15 μM to about 16 μM,and ranges between any two of these values or less than any one of thesevalues. In some embodiments, the wire mesh has a thickness from about 5to about 20 μM. In some embodiments, the wire mesh has a thickness fromabout 14 to about 17 μM.

The wires of the mesh may be configured to have the desired elasticityor stiffness, which may be expressed in terms of their Young's Modulus.In some embodiments, the first nickel alloy wire has a Young's Modulusof greater than 120 GPa. This includes a Young's Modulus of greater than130 GPa, greater than 140 GPa, greater than 16,20 GPa, greater than 180GPa, greater than 200 GPa, and greater than 220 GPa. In someembodiments, the first nickel alloy wire has a Young's Modulus of about140 GPa, about 160 GPa, about 180 GPa, about 200 GPa, about 210 GPa,about 220 GPa, about 240 GPa, or about 280 GPa. In other embodiments,the first nickel alloy wire has a Young's Modulus of from about 140 GPato about 300 GPa. This includes a Young's Modulus of from about 150 GPato about 290 GPa, from about 160 GPa to about 280 GPa, from about 180GPa to about 240 GPa, from about 200 GPa to about 220 GPa, or from about210 GPa to about 215 GPa, and ranges between any two of these values orless than any one of these values. In some embodiments, the first nickelalloy wire has a Young's Modulus of greater than 140 GPa. In someembodiments, the first nickel alloy wire has a Young's Modulus ofgreater than 180 GPa. In some embodiments, the first nickel alloy wirehas a Young's Modulus of greater than 200 GPa. In some embodiments, thefirst nickel alloy wire has a Young's Modulus of about 210 GPa. In someembodiments, the first nickel alloy wire has a Young's Modulus of fromabout 180 GPa to about 240 GPa.

In another aspect, an expanded metal mesh is provided. The expandedmetal mesh may be produced by expanding a sheet or coil of metal ofappropriate thickness by a suitable expansion factor of at least 10times its original area. A large number of small cuts are made in thesheet and the sheet is stretched out so that the material forms openingsof the desired shape and size. The sheet or coil may be annealed priorto or after the expansion. The expanded metal mesh may be made from anysuitable metal or alloy, including for example, pure nickel, or the samematerial as the first nickel alloy wire or the second nickel alloy wire.In some embodiments, the expanded metal mesh includes a nickel metalalloy comprising at least 90 wt % nickel and less than 10 wt % aluminum.In other embodiments, the expanded metal mesh includes a nickel metalalloy which includes from about 93 wt % to about 97 wt % nickel and fromabout 3 wt % to about 7 wt % aluminum.

The wire mesh of the disclosed embodiments may be included as acomponent in a conventional electrochemical cell such as batteries.These include, for example, galvanic cells, such as in metal-air cells,e.g., zinc-air cell. Metal-air cells comprising the wire mesh describedherein may usefully be constructed as button cells for the variousapplications such as hearing aid batteries, and in watches, clocks,timers, calculators, laser pointers, toys, and other novelties. It shallbe understood, however, that the present invention has application toelectrochemical cells other than button cells. For example, the wiremesh may find application in any metal air cell using flat, bent, orcylindrical electrodes. Among the cylindrical metal-air cells, thecathode active material is applicable to those shaped for any button,hearing aid, AA, AAA, AAAA, C, or D cells. Use of the wire mesh ascomponents in other forms of electrochemical cells is also contemplated.

In one embodiment, a cathode current collector for an air battery mayinclude the wire mesh described above. In some embodiments, the wiremesh is included as a cathode current collector in a zinc-air battery.In one embodiment, the zinc-air battery may be configured in accordanceor consistent with conventional zinc-air battery cell designs, but withthe improvements provided in detail herein. For example, in variousembodiments the zinc-air battery may be designed to specificationssuitable for a zinc-air button size battery.

In one embodiment, a cathode current collector which includes a warpcomposed of a first nickel alloy wire having a first peak tensilestrength and a weft composed of a wire which includes nickel and havinga second peak tensile strength is provided. In some embodiments, thefirst peak tensile strength is greater than or equal to the second peaktensile strength. In some embodiments, the current collector is acathode current collector. In some embodiments, the current collector isa cathode current collector in a zinc-air battery. Apart from the meshdescribed herein, the current collector may take a variety of forms. Forexample, the current collector may be a wire, bar, strip, perforatedsheet, and the like. In some embodiments, the current collector is amesh wire current collector.

The mesh wire current collector may be included in a cathode disc alongwith other components such as a porous diffusion layer and a cathodelayer including carbon. When the cathode disc, containing a mesh wirecurrent collector, is inserted into a cathode can, the contact edges ofthe wire within the cut disc resist buckling, leading to better contactbetween the current collector and the can walls. The Ni-Alloy wire andthe wire meshes described herein exhibit excellent tensile strength atbreak and excellent tensile modulus of elasticity as well as inertnessto chemicals, e.g., electrolytes and caustic additives in theelectrolytes. The mesh wire cathode current collector described hereinmaintains better contact to the sidewall of the can, resulting in lowerimpedance and lower cell scrap.

In one aspect, a zinc-air battery is provided that includes a wire meshcurrent collector having a warp and a weft. The warp includes a firstnickel alloy wire having a first peak tensile strength, and the weftincludes a wire comprising nickel and having a second peak tensilestrength, such that the first peak tensile strength is greater than orequal to the second peak tensile strength. The first nickel alloy wireand the wire including nickel are as described herein. The zinc-airbattery further includes an anode comprising zinc, an electrolyte, and aseparator.

The anode may contain zinc or a zinc alloy functioning as a negativeelectrode active material. In some embodiments, the anode includes amercury-free zinc alloy powder. The anode may be in any form or shapesuch as particulate, plate, and gel. The zinc alloy may be amalgamatedor mercury-free alloys with magnesium, aluminum, lithium, bismuth,indium, lead, or the like. The amount of the zinc alloy is notparticularly limited as long as the alloy ensures a desired performanceas the negative electrode active material. Preferable zinc alloy is amercury-free zinc alloy without mercury and lead, and those containingaluminum, bismuth, indium, or a combination of any two or more thereof.The anode may be supported by a suitable current collector composedconductive material plate or mesh, including the wire mesh describedherein. Illustrative materials for the anode current collector includenickel-based materials. For example, alloys of nickel and aluminum maybe used. Other metals that may be included in the alloy include, but arenot limited to, copper, iron, manganese, and titanium, as well asnon-metals such as, but not limited to, silicon, carbon, and sulfur.Illustrative materials are commercially available as Duranickel® alloy301, from Special Metals Corporation, Huntington, W. Va.

A variety of electrolyte solutions generally used for the zinc-airbattery may be used as the electrolyte solution. Examples of theelectrolyte solution include alkaline metal hydroxide aqueous solutionssuch as a potassium hydroxide aqueous solution and a sodium hydroxideaqueous solution; solutions containing zinc chloride or zincperchlorate; nonaqueous solvents containing zinc perchlorate; andnonaqueous solvents containing zinc bis(trifluoromethylsulfonyl)imide.In some embodiments, the electrolyte includes an alkaline metalhydroxide aqueous solution, for example, potassium hydroxide solution.In some embodiments, a potassium hydroxide aqueous solution containingpotassium hydroxide of from 30 to 45 wt % is used as the electrolyte. Insome embodiments, the electrolyte includes an amphotericfluorosurfactant such as Capstone® FS-50, Chemguard S-111, ChemguardS-500, APFS-14, or a combination of any two or more thereof. Theelectrolyte may further include a surfactant such as e.g., hexyldiphenyl oxide disulfonic acid. The electrolyte may also include acorrosion inhibitor, a gelling agent, zinc oxide, potassium hydroxide,sodium hydroxide, indium hydroxide, polyacrylate polymer, or acombination of any two or more thereof. In some embodiments, theelectrolyte includes an potassium hydroxide aqueous solution.

The zinc-air battery may include a separator between the air cathode andthe zinc anode, which is designed for preventing short-circuitingbetween the two electrodes. The separator may include a permeablemembrane or a porous film made of non-conductive material. The separatormay be made of any alkaline resistant material, including, but notlimited to, polypropylene, Teflon™, nylon, polyethylene, polyvinylchloride, polystyrene, polyphenylene oxide, cellophane, oracrylonitrile, and combinations thereof. In some embodiments, theseparator includes polypropylene.

In one aspect, a zinc-air battery is provided, which includes a wiremesh current collector wherein a metal of the wire mesh is substantiallyinsoluble in an aqueous caustic electrolyte. In one embodiment, the wiremesh has less than 40 wt %, less than 30 wt %, less than 10 wt %, lessthan 5 wt % or less than 2 wt % solubility in the aqueous causticelectrolyte.

In one aspect, a zinc-air battery is provided, which includes a wiremesh current collector comprising a wire warp and a wire weft, whereinthe current collector exhibits at least one or more of the followingproperties: (a) a metal of the wire mesh is substantially insoluble inan aqueous caustic electrolyte; (b) a wire of the warp or weft prior toincorporation in the mesh exhibits a hardness of from about 130 to about375 Brinell; (c) a wire of the warp or weft prior to incorporation inthe mesh exhibits a resistivity of from about 2×10⁻⁷ Ωm to about 5×10⁻⁷Ωm at 20° C.; (d) a wire of the warp or weft prior to incorporation inthe mesh exhibits a peak tensile strength of greater than 140 ksi; and(e) a wire of the warp or weft prior to incorporation in the meshexhibits a Young's Modulus of from about 180 GPa to about 240 GPa.

Turning to the figures, a zinc-air battery cell of the presentdisclosure is illustrated in FIG. 2, although other designs should notbe so limited. Referring specifically to FIG. 2, the cell 10 of thezinc-air battery, the negative electrode contains the anode can assembly22, with an anode can 24 including an electrochemically reactive anode26 contained therein and an insulating gasket 60. The anode can 24 has abase wall 28, and circumferential downwardly-depending side wall 30.Side walls 30 terminate in a circumferential can foot 36. The base walland side walls 30 generally define the anode cavity 38 within the anodecan 24, which cavity contains the anode 26.

The cathode 42 comprises the area from below the separator 74 to thecathode can 44. This cathode 42 area includes the porous diffusion layer57 and the cathode active layer 72. The wire mesh is included as acurrent collector in the cathode active layer 72. Cathode can 44 has abottom 46, and a circumferential upstanding side wall 47. Bottom 46 hasa generally flat inner surface 48, a generally flat outer surface 50,and an outer perimeter 52 defined on the flat outer surface 50. Aplurality of air ports 54 extend through the bottom 46 of the cathodecan 44, providing avenues for traverse of oxygen through the bottom 46into the adjacent cathode can assembly 40. An air reservoir 55 spacesthe cathode can assembly 40 from bottom 46 and the corresponding airports 54. A porous diffusion layer 57 and a cellulose air diffusionlayer 32 fill the air reservoir 55. Side wall 47 of the cathode can hasan inner surface 56 and an outer surface 58.

The anode can assembly 22 is electrically insulated from the cathode canassembly 40 by an insulating gasket 60. Insulating gasket 60 includes acircumferential side wall 62 disposed between the upstanding side wall47 of the cathode can and the downwardly-depending side wall 30 of theanode can. An insulating gasket foot 64 is disposed generally betweenthe can foot 36 of the anode can and the cathode can assembly 40. Aninsulating gasket top 66 is positioned at the locus where the side wall62 of insulating gasket 60 extends from between the side walls 30 and 47adjacent the top of the cell.

The outer surface 68 of the cell 10 is thus defined by portions of theouter surface of the top of the anode can 24, outer surface 58 of theside wall 47 of the cathode can 44, outer surface 50 of the bottom ofthe cathode can 44, and the top 66 of the insulating gasket 60.

In one embodiment, porous diffusion layer 57 is a micro-poroushydrophobic polymeric material such as a polytetrafluoroethylene (PTFE)membrane about 25 to about 100 microns thick, which permits passage ofair therethrough and which is generally impervious to batteryelectrolyte. In one embodiment, the porous diffusion layer 57 isTeflon™. In some embodiments, the porous diffusion layer 57, incombination with the air ports 54, is used to efficiently transportoxygen to the active reaction surface area of the cathode assembly.

In one embodiment, the cellulose air diffusion layer 32 is locatedunderneath the porous diffusion layer 57 and acts as a protectivelateral air diffusion layer. Specifically, when the cell is activated,the anode can assembly 22 presses down on the separator 74 and thecellulose air diffusion layer 32 helps to protect the air ports 54 frombeing completely covered. In one embodiment, the thickness of thecathode assembly between the separator 74 and the porous diffusion layer57 is as small as possible.

In another embodiment, the zinc-air battery may be prepared by any meansknown in the art, so long as the resulting battery does not conflictwith the disclosures presented herein. Thus, the present disclosureincludes a method of preparing a zinc-air battery including thecomponents and their respective concentrations as discussed throughoutthe entirety of this disclosure.

Various aspects of the invention are set out in the followingembodiments.

Embodiment A. A wire mesh comprising: a warp comprising a first nickelalloy wire having a first peak tensile strength; a weft comprising awire comprising nickel and having a second peak tensile strength;wherein: the first peak tensile strength is greater than or equal to thesecond peak tensile strength.

Embodiment B. The wire mesh of Embodiment A, wherein the wire comprisingnickel has greater than 99% nickel.

Embodiment C. The wire mesh of Embodiment A or B, wherein the wirecomprising nickel has greater than 99.5% nickel.

Embodiment D. The wire mesh of any one of Embodiments A-C, wherein thefirst nickel alloy wire comprises at least 90 wt % nickel and less than10 wt % aluminum.

Embodiment E. The wire mesh of any one of Embodiments A-D, wherein thefirst nickel alloy wire comprises from about 93 wt % to about 97 wt %nickel and from about 3 wt % to about 7 wt % aluminum.

Embodiment F. The wire mesh of any one of Embodiments A-E, wherein thefirst nickel alloy wire further comprises at least one of copper, iron,manganese, carbon, silicon, sulfur, and titanium.

Embodiment G. The wire mesh of any one of Embodiments A-F, wherein thefirst nickel alloy wire has a resistivity of from about 2×10⁻⁷ Ωm toabout 5×10⁻⁷ Ωm at 20° C.

Embodiment H. The wire mesh of any one of Embodiments A-G, wherein thewire comprising nickel is an annealed wire.

Embodiment I. The wire mesh of any one of Embodiments A-H, wherein thefirst nickel alloy wire has a peak tensile strength of greater than 140ksi.

Embodiment J. The wire mesh of any one of Embodiments A-I, wherein thefirst nickel alloy wire has a peak tensile strength of greater than 180ksi.

Embodiment K. The wire mesh of any one of Embodiments A-J, wherein thefirst nickel alloy wire has a peak tensile strength of greater than 200ksi.

Embodiment L. The wire mesh of any one of Embodiments A-K, wherein thefirst nickel alloy wire has a peak tensile strength of greater than 210ksi.

Embodiment M. The wire mesh of any one of Embodiments A-L, wherein thefirst nickel alloy wire has a peak tensile strength of less than 350ksi.

Embodiment N. The wire mesh of any one of Embodiments A-M, wherein thefirst nickel alloy wire has a peak tensile strength of less than 300ksi.

Embodiment O. The wire mesh of any one of Embodiments A-N, wherein thefirst nickel alloy wire has a peak tensile strength of less than 230ksi.

Embodiment P. The wire mesh of any one of Embodiments A-O, wherein thefirst nickel alloy wire has a peak tensile strength of from about 140ksi to about 250 ksi.

Embodiment Q. The wire mesh of any one of Embodiments A-P, wherein thefirst nickel alloy wire has a peak tensile strength of from about 200ksi to about 225 ksi.

Embodiment R. The wire mesh of any one of Embodiments A-Q, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 60ksi.

Embodiment S. The wire mesh of any one of Embodiments A-R, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 80ksi.

Embodiment T. The wire mesh of any one of Embodiments A-S, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 100ksi.

Embodiment U. The wire mesh of any one of Embodiments A-T, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 120ksi.

Embodiment V. The wire mesh of any one of Embodiments A-U, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 150ksi.

Embodiment W. The wire mesh of any one of Embodiments A-V, wherein thesecond nickel alloy wire has a peak tensile strength of greater than 200ksi.

Embodiment X. The wire mesh of any one of Embodiments A-W, wherein thesecond nickel alloy wire has a peak tensile strength of from about 80ksi to about 150 ksi.

Embodiment Y. The wire mesh of any one of Embodiments A-X, wherein thesecond nickel alloy wire has a peak tensile strength of from about 110ksi to about 140 ksi.

Embodiment Z. The wire mesh of any one of Embodiments A-Y, wherein themesh count of the wire mesh is from about 16×16 wires per inch to about60×60 wires per inch.

Embodiment AA. The wire mesh of any one of Embodiments A-Z, wherein themesh count of the wire mesh is from about 30×30 wires per inch to about40×40 wires per inch.

Embodiment BB. The wire mesh of any one of Embodiments A-AA, wherein themesh count of the wire mesh is from about 16×60 wires per inch to about60×16 wires per inch.

Embodiment CC. The wire mesh of any one of Embodiments A-BB, wherein thewire comprising nickel has a greater cross-sectional diameter than thefirst nickel alloy wire.

Embodiment DD. The wire mesh of any one of Embodiments A-CC, wherein thecross-section diameters of the wire comprising nickel and the firstnickel alloy wire have a ratio of about 1:1 to about 2:1.

Embodiment EE. The wire mesh of any one of Embodiments A-DD, wherein thecross-section diameters of the wire comprising nickel and the firstnickel alloy wire are equal or about equal.

Embodiment FF. The wire mesh of any one of Embodiments A-EE, wherein thewire comprising nickel is a second nickel alloy wire.

Embodiment GG. The wire mesh of any one of Embodiment FF, wherein firstand the second nickel alloy wires are of the same wire.

Embodiment HH. The wire mesh of any one of Embodiments A-GG having amesh density from about 0.1 to about 0.5.

Embodiment II. The wire mesh of any one of Embodiments A-HH which isformed by cold calendaring of the warp and the weft, which is formed bythermal bonding, or which is formed by coating of the mesh with anothermetal.

Embodiment JJ. The wire mesh of any one of Embodiments A-II which is awoven mesh comprising a plain weave, a basket weave, a twill weave, asatin weave, a herringbone weave, a leno weave, a rep weave, a ribweave, a warp rib weave, a Dutch weave, or a velour weave.

Embodiment KK. The wire mesh of any one of Embodiments A-JJ having athickness from about 5 to about 20 μM.

Embodiment LL. The wire mesh of any one of Embodiments A-KK having athickness from about 14 to about 17 μM.

Embodiment MM. The wire mesh of any one of Embodiments A-LL, wherein thefirst nickel alloy wire has a Young's Modulus of greater than 140 GPa.

Embodiment NN. The wire mesh of any one of Embodiments A-MM, wherein thefirst nickel alloy wire has a Young's Modulus of greater than 180 GPa.

Embodiment OO. The wire mesh of any one of Embodiments A-NN, wherein thefirst nickel alloy wire has a Young's Modulus of greater than 200 GPa.

Embodiment PP. The wire mesh of any one of Embodiments A-OO, wherein thefirst nickel alloy wire has a Young's Modulus of about 210 GPa.

Embodiment QQ. The wire mesh of any one of Embodiments A-PP, wherein thefirst nickel alloy wire has a Young's Modulus of from about 180 GPa toabout 240 GPa.

Embodiment RR. The wire mesh of any one of Embodiments A-QQ, wherein thewarp exhibits a microhardness from about 180 kgf/mm² to about 350kgf/mm², and the weft exhibits a microhardness from about about 90kgf/mm² to about 150 kgf/mm².

Embodiment SS. An expanded metal mesh comprising a nickel metal alloycomprising at least 90 wt % nickel and less than 10 wt % aluminum.

Embodiment TT. The expanded metal mesh of Embodiment SS, wherein thenickel metal alloy comprises from about 93 wt % to about 97 wt % nickeland from about 3 wt % to about 7 wt % aluminum.

Embodiment UU. The expanded metal mesh of any one of Embodiments SS-TT,wherein the nickel metal alloy further comprises at least one of copper,iron, manganese, carbon, silicon, sulfur, and titanium.

Embodiment VV. The expanded metal mesh of any one of Embodiments SS-UU,wherein the nickel metal alloy comprises of nickel metal alloy wires.

Embodiment WW. The expanded metal mesh of any one of Embodiments SS-VV,wherein the nickel metal alloy wire has a resistivity of from about2×10-7 Ωm to about 5×10-7 Ωm at 20° C.

Embodiment XX. The expanded metal mesh of any one of Embodiments SS-WW,wherein the nickel metal alloy wire has a peak tensile strength ofgreater than 140 ksi.

Embodiment YY. The expanded metal mesh of any one of Embodiments SS-XX,wherein the nickel metal alloy wire has a peak tensile strength ofgreater than 180 ksi.

Embodiment ZZ. The expanded metal mesh of any one of Embodiments SS-YY,wherein the nickel metal alloy wire has a peak tensile strength ofgreater than 200 ksi.

Embodiment AAA. The expanded metal mesh of any one of Embodiments SS-ZZ,wherein the nickel metal alloy wire has a peak tensile strength ofgreater than 210 ksi.

Embodiment BBB. The expanded metal mesh of any one of EmbodimentsSS-AAA, wherein the nickel metal alloy wire has a peak tensile strengthof less than 350 ksi.

Embodiment CCC. The expanded metal mesh of any one of EmbodimentsSS-BBB, wherein the nickel metal alloy wire has a peak tensile strengthof less than 300 ksi.

Embodiment DDD. The expanded metal mesh of any one of EmbodimentsSS-CCC, wherein the nickel metal alloy wire has a peak tensile strengthof less than 230 ksi.

Embodiment EEE. The expanded metal mesh of any one of EmbodimentsSS-DDD, wherein the nickel metal alloy wire has a peak tensile strengthof from about 140 ksi to about 250 ksi.

Embodiment FFF. The expanded metal mesh of any one of EmbodimentsSS-EEE, wherein the nickel metal alloy wire has a peak tensile strengthof from about 200 ksi to about 225 ksi.

Embodiment GGG. A zinc-air battery comprising: a wire mesh currentcollector comprising: a warp comprising a first nickel alloy wire havinga first peak tensile strength; a weft comprising a wire comprisingnickel and having a second peak tensile strength; wherein: the firstpeak tensile strength is greater than or equal to the second peaktensile strength. Or, a zinc-air battery comprising the wire mesh of anyone of Embodiments A-RR or Embodiments SS-FFF.

Embodiment HHH. The zinc-air battery of Embodiment FFF furthercomprising an anode comprising zinc, an electrolyte, and a separator.

Embodiment III. A zinc-air battery comprising: a wire mesh currentcollector comprising: a wire warp; a wire weft; wherein at least two ofthe following are exhibited: a metal of the wire mesh is substantiallyinsoluble in an aqueous caustic electrolyte; a wire of the warp or weftprior to incorporation in the mesh exhibits a hardness of from about 130to about 375 Brinell; a wire of the warp or weft prior to incorporationin the mesh exhibits a resistivity of from about 2×10⁻⁷ Ωm to about5×10⁻⁷ Ωm at 20° C.; a wire of the warp or weft prior to incorporationin the mesh exhibits a peak tensile strength of greater than 140 ksi;and a wire of the warp or weft prior to incorporation in the meshexhibits a Young's Modulus of from about 180 GPa to about 240 GPa.

Embodiment JJJ. A zinc-air battery comprising: a wire mesh currentcollector comprising: a wire warp comprising a first nickel alloy; awire weft comprising a second nickel alloy; wherein the first and secondnickel alloys are substantially insoluble in an aqueous causticelectrolyte; the warp exhibits a microhardness from about 180 kgf/mm² toabout 350 kgf/mm², and the weft exhibits a microhardness from aboutabout 90 kgf/mm² to about 150 kgf/mm²; a wire of the warp prior toincorporation in the mesh exhibits a resistivity of from about 2×10⁻⁷ Ωmto about 5×10⁻⁷ Ωm at 20° C.; a wire of the warp prior to incorporationin the mesh exhibits a peak tensile strength of greater than 140 ksi;and a wire of the warp prior to incorporation in the mesh exhibits aYoung's Modulus of from about 180 GPa to about 240 GPa.

The wire mesh described herein has several advantageous properties suchas for example, improved dimensional integrity, high corrosionresistance, high oxidation resistance, good structural uniformity andhigh wear resistance. These wires when used as current collectors inbatteries exhibit advantages such as low impedance and low scrap value.

The present invention, thus generally described, will be understood morereadily by reference to the following examples, which are provided byway of illustration and are not intended to be limiting of the presentinvention.

EXAMPLES

Example 1: Preparation of the wire mesh. In preparing a wire from thefirst nickel alloy or the wire containing nickel as specified for use aswarp or weft wire, the wire is drawn to required gauge and issufficiently annealed prior to weaving. Wire rod is drawn and annealedto differing degrees to the final desired wire gauge. The wire is woveninto a mesh on looms in a customary fashion.

Example 2: Preparation of the zinc-air battery. The composite meshstructure (cathode) obtained in Example 1, is fed, in strip form,through a punch/die blanking set. The composite mesh structure is cutinto a circular disc of desired diameter and inserted into a metal canthat constrains the circular disc both radially and axially. The anode,which may contain an anode material, an electrolyte and other additives,is inserted into the cathode portion and crimped closed.

Example 3: Comparison of zinc-air batteries. In the following examples,zinc-air battery cells were tested using a control cathode and ancathode having the nickel alloy wire mesh current collector. The controlcathode, included a nickel current collector. After battery fabricationand crimping of the anode to the cathode, impedance measurements wereobtained. The percentage of assembled batteries having an impedancemeasurement above a given threshold was graphed v. the crimp height forboth the nickel alloy current collector batteries and the controlbatteries. The graph is provided in FIG. 3. As will be noted, as thecrimp height decreases, percentage of impedance failures increases forthe controls, while very little impact is noted for the nickel alloywire mesh current collector batteries.

While certain embodiments have been illustrated and described, it shouldbe understood that changes and modifications may be made therein inaccordance with ordinary skill in the art without departing from thetechnology in its broader aspects as defined in the following claims.

The embodiments, illustratively described herein may suitably bepracticed in the absence of any element or elements, limitation orlimitations, not specifically disclosed herein. Thus, for example, theterms “comprising,” “including,” “containing,” etc. shall be readexpansively and without limitation. Additionally, the terms andexpressions employed herein have been used as terms of description andnot of limitation, and there is no intention in the use of such termsand expressions of excluding any equivalents of the features shown anddescribed or portions thereof, but it is recognized that variousmodifications are possible within the scope of the claimed technology.Additionally, the phrase “consisting essentially of” will be understoodto include those elements specifically recited and those additionalelements that do not materially affect the basic and novelcharacteristics of the claimed technology. The phrase “consisting of”excludes any element not specified.

The present disclosure is not to be limited in terms of the particularembodiments described in this application. Many modifications andvariations may be made without departing from its spirit and scope, aswill be apparent to those skilled in the art. Functionally equivalentmethods and compositions within the scope of the disclosure, in additionto those enumerated herein, will be apparent to those skilled in the artfrom the foregoing descriptions. Such modifications and variations areintended to fall within the scope of the appended claims. The presentdisclosure is to be limited only by the terms of the appended claims,along with the full scope of equivalents to which such claims areentitled. It is to be understood that this disclosure is not limited toparticular methods, reagents, compounds compositions or biologicalsystems, which may of course vary. It is also to be understood that theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to be limiting.

In addition, where features or aspects of the disclosure are describedin terms of Markush groups, those skilled in the art will recognize thatthe disclosure is also thereby described in terms of any individualmember or subgroup of members of the Markush group.

As will be understood by one skilled in the art, for any and allpurposes, particularly in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range may be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein maybe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the like,include the number recited and refer to ranges which may be subsequentlybroken down into subranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember.

All publications, patent applications, issued patents, and otherdocuments referred to in this specification are herein incorporated byreference as if each individual publication, patent application, issuedpatent, or other document was specifically and individually indicated tobe incorporated by reference in its entirety. Definitions that arecontained in text incorporated by reference are excluded to the extentthat they contradict definitions in this disclosure.

Other embodiments are set forth in the following claims.

What is claimed is:
 1. An expanded metal mesh comprising a nickel metalalloy comprising 90 wt % to 99 wt % nickel and 1 wt % to 10 wt %aluminum.
 2. The expanded metal mesh of claim 1, wherein the nickelmetal alloy comprises from about 93 wt % to about 97 wt % nickel andfrom about 3 wt % to about 7 wt % aluminum.
 3. The expanded metal meshof claim 1, wherein the nickel metal alloy further comprises at leastone of copper, iron, manganese, carbon, silicon, sulfur, and titanium.4. The expanded metal mesh of claim 1, wherein the nickel metal alloywire has a resistivity of from about 2×10-7 Ωm to about 5×10-7 Ωm at 20°C.
 5. The expanded metal mesh of claim 1, wherein the nickel alloy wirehas a peak tensile strength of greater than 140 ksi.
 6. The expandedmetal mesh of claim 1, wherein the nickel alloy wire has a peak tensilestrength of greater than 180 ksi.
 7. The expanded metal mesh of claim 1,wherein the nickel alloy wire has a peak tensile strength of greaterthan 200 ksi.
 8. The expanded metal mesh of claim 1, wherein the nickelalloy wire has a peak tensile strength of greater than 210 ksi.
 9. Theexpanded metal mesh of claim 1, wherein the nickel alloy wire has a peaktensile strength of less than 350 ksi.
 10. The expanded metal mesh ofclaim 1, wherein the nickel alloy wire has a peak tensile strength ofless than 300 ksi.
 11. The expanded metal mesh of claim 1, wherein thenickel alloy wire has a peak tensile strength of less than 230 ksi. 12.The expanded metal mesh of claim 1, wherein the first nickel alloy wirehas a peak tensile strength of from about 140 ksi to about 250 ksi. 13.The expanded metal mesh of claim 1, wherein the first nickel alloy wirehas a peak tensile strength of from about 200 ksi to about 225 ksi. 14.A method of producing an expanded metal mesh comprising: expanding asheet or coil of metal of by an expansion factor of at least 10 timesits original area; introducing small cuts in to the sheet; andstretching the cut sheet to provide and expanded metal mesh.
 15. Themethod of claim 14, further comprising annealing the sheet or coil priorto or after the expansion.